Fire resistant fabric material

ABSTRACT

A fire resistant fabric material comprising a substrate having an ionic charge which is coated with a coating having essentially the same ionic charge. The coating consists essentially of a filler material comprising clay and a binder material. The substrate is preferably fiberglass, the filler material may further comprise at least one additional filler selected from the group consisting of decabromodiphenyloxide, antimony trioxide, fly ash, charged calcium carbonate, mica, glass microspheres and ceramic microspheres and mixtures thereof and the binder material is preferably acrylic latex.

BACKGROUND OF THE INVENTION

[0001] This invention relates to fire resistant fabric materialscomprising a substrate having an ionic charge coated with a coatinghaving essentially the same charge and consisting essentially of afiller material and a binder material. The filler material includesclay.

[0002] For many years substrates such as fiberglass have been coatedwith various compositions to produce materials having utility in, amongother applications, the building industry. U.S. Pat. No. 5,001,005relates to structural laminates made with facing sheets. The laminatesdescribed in that patent include thermosetting plastic foam and haveplanar facing sheets comprising 60% to 90% by weight glass fibers(exclusive of glass micro-fibers), 10% to 40% by weight non-glass fillermaterial and 1% to 30% by weight non-asphaltic binder material. Thefiller materials are indicated as being clay, mica, talc, limestone(calcium carbonate), gypsum (calcium sulfate), aluminum trihydrate(ATH), antimony trioxide, cellulose fibers, plastic polymer fibers or acombination of any two or more of those substances. The patent furthernotes that the filler materials are bonded to the glass fibers usingbinders such as urea-, phenol- or melamine-formaldehyde resins (UF, PF,and MF resins), or a modified acrylic or polyester resin. Ordinarypolymer latexes used according to the disclosure areStyrene-Butadiene-Rubber (SBR), Ethylene-Vinyl-Chloride (EVCl),PolyVinylidene Chloride (PvdC), modified PolyVinyl Chloride (PVC),PolyVinyl Alcohol (PVOH), and PolyVinyl Acetate (PVA). The glass fibers,non-glass filler material and non-asphaltic binder are all mixedtogether to form the facer sheets.

[0003] U.S. Pat. No. 4,745,032 discloses an acrylic coating comprised ofone acrylic underlying resin which includes fly ash and an overlyingacrylic resin which differs from the underlying resin.

[0004] U.S. Pat. No. 4,229,329 discloses a fire retardant coatingcomposition comprising fly ash and vinyl acrylic polymer emulsion. Thefly ash is 24 to 50% of the composition. The composition may alsopreferably contain one or more of a dispersant, a defoamer, aplasticizer, a thickener, a drying agent, a preservative, a fungicideand an ingredient to control the pH of the composition and therebyinhibit corrosion of any metal surface to which the composition isapplied.

[0005] U.S. Pat. No. 4,784,897 discloses a cover layer material on abasis of a matting or fabric which is especially for the production ofgypsum boards and polyurethane hard foam boards. The cover layermaterial has a coating on one side which comprises 70% to 94% powderedinorganic material, such as calcium carbonate, and 6% to 30% binder. Inaddition, thickening agents and cross-linking agents are added and ahigh density matting is used.

[0006] U.S. Pat. No. 4,495,238 discloses a fire resistant thermalinsulating composite structure comprised of a mixture of from about of50% to 94% by weight of inorganic microfibers, particularly glass, andabout 50% to 6% by weight of heat resistant binding agent.

[0007] U.S. Pat. No. 5,091,243 discloses a fire barrier fabriccomprising a substrate formed of corespun yarns and a coating carried byone surface of the substrate. The coating comprises a carbonificcompound, a catalyst and a source of a non-flammable gas. The coatingadditionally comprises thickening agents and blowing agents.

[0008] Many different coating compositions have been formulated over theyears but often such compositions would bleed through substrates, suchas fiberglass substrates, if the substrates were coated on just oneside, unless the compositions had a high binder content and/or includedviscosity modifiers to enhance the viscosity of the coating composition.To prevent bleed through, such coating compositions sometimes had theirviscosity increased by blowing or whipping air into the compositions.Although such blown compositions did not bleed through to the other sideof mats such as fiberglass mats, the raw material costs for thecompositions were high because of the numbers of constituent elementsinvolved.

[0009] U.S. Pat. No. 5,965,257, the entire disclosure of which isincorporated herein by reference, discloses a structural article havinga coating which includes only two major constituents, while eliminatingthe need for viscosity modifiers, for stabilizers or for blowing. Thestructural article of U.S. Pat. No. 5,965,257 is made by coating asubstrate having an ionic charge with a coating having essentially thesame iconic charge. The coating consists essentially of a fillermaterial and a binder material. By coating the substrate with a coatinghaving essentially the same ionic charge, the patentee developed a zerobleed through product while using only two major ingredients in thecoating and eliminating the need for costly and time consumingprocessing steps such as blowing. Structural articles may thus beproduced having a low binder content and no viscosity modifiers. U.S.Pat. No. 5,965,257 issued to Elk Corporation of Dallas, the assignee ofthe present application. Elk produces a product in accordance with theinvention of U.S. Pat. No. 5,965,257 which is marketed as VersaShield®.

[0010] As indicated in U.S. Pat. No. 5,965,257, VersaShield® has manyuses. However, it has been found that the products of U.S. Pat. No.5,965,257 are unable to provide a satisfactory fabric material becausethey lack adequate drapability characteristics. The applicant hasdiscovered, however, that by including clay as a filler component in thecoating of the article, a fire resistant fabric material may be producedwhich has satisfactory flexibility, pliability and drapabilitycharacteristics.

SUMMARY OF THE INVENTION

[0011] The present invention relates to a fire resistant fabric materialcomprising a substrate having an ionic charge coated with a coating haveessentially the same ionic charge. The substrate may be any suitablereinforcement material capable of withstanding processing temperaturesand is preferably fiberglass. The coating is comprised principally of afiller and a binder. The binder is preferably acrylic latex and thefiller comprises clay and may further include an additional fillerselected from the group consisting of antimony trioxide,decabromodiphenyloxide, charged calcium carbonate, fly ash, mica, glassor ceramic microspheres and mixtures thereof.

[0012] The fire resistant fabric material may be used on its own or inconjunction with (e.g. as a liner for) a decorative fabric which mayitself be fire resistant. The present invention also relates to anarticle of manufacture comprising the fire resistant fabric materialincluding, inter alia, mattress fabrics, mattress covers, upholsteredarticles, building materials, bedroom articles, (including children'sbedroom articles), draperies, carpets, tents, awnings, fire shelters,sleeping bags, ironing board covers, barbecue grill covers, fireresistant gloves, engine liners, and fire-resistant clothing for racecar drivers, fire fighters, jet fighter pilots, and the like. The use ofthe fire resistant fabric materials of the present invention formanufacturing fabrics for use in articles such as mattresses, cribs,drapes and upholstered furniture, may enable the article to exceedcurrent flammability standards for these types of articles.

DETAILED DESCRIPTION

[0013] In accordance with the invention, a fire resistant fabricmaterial is made by coating a substrate having an ionic charge with acoating having essentially the same ionic charge. The coating consistsessentially of a filler material and a binder material. By coating thesubstrate with a coating having essentially the same ionic charge, theapplicant has developed a fire resistant fabric material while usingmainly two major ingredients in the coating and eliminating the need forviscosity modifiers, thickening agents and costly and time consumingprocessing steps such as blowing.

[0014] The coated substrate of the present invention may be any suitablereinforcement material capable of withstanding processing temperatures,such as glass fibers, polyester fibers, cellulosic fibers, asbestos,steel fibers, alumina fibers, ceramic fibers, nylon fibers, graphitefibers, wool fibers, boron fibers, carbon fibers, jute fibers,polyolefin fibers, polystyrene fibers, acrylic fibers,phenolformaldehyde resin fibers, aromatic and aliphatic polyamidefibers, polyacrylamide fibers, polyacrylimide fibers or mixtures thereofwhich may include bicomponent fibers.

[0015] Examples of substrates in accordance with the invention include,inter alia, glass, fiberglass, ceramics, graphite (carbon), PBI(polybenzimidazole), PTFE, polyaramides, such as KEVLAR™ and NOMEX™,metals including metal wire or mesh, polyolefins such as TYVEK™,polyesters such as DACRON™ or REEMAY™, polyamides, polyimides,thermoplastics such as KYNAR™ and TEFZEL™, polyether sulfones, polyetherimide, polyether ketones, novoloid phenolic fibers such as KYNOL™, KoSa™polyester fibers, JM-137 M glass fibers, Owens-Corning M glass,Owens-Corning K glass fibers, Owens-Corning H glass fibers, Evanite 413Mglass microfibers, Evanite 719 glass microfibers, cellulosic fibers,cotton, asbestos and other natural as well as synthetic fibers. Thesubstrate may comprise a yarn, filament, monofilament or other fibrousmaterial either as such or assembled as a textile, or any woven,non-woven, knitted, matted, felted, etc. material. The polyolefin may bepolyvinyl alcohol, polypropylene, polyethylene, polyvinyl chloride,polyurethane, etc. alone or in combination with one another. Theacrylics may be DYNEL, ACRILAN and/or ORLON. RHOPLEX AC-22 and RHOPLEXAC-507 are acrylic resins sold by Rohm and Haas which nay also may beused. The cellulosic fibers may be natural cellulose such as wood pulp,newsprint, Kraft pulp and cotton and/or chemically processed cellulosesuch as rayon and/or lyocell. Nonlimiting examples of non-wovenmaterials that may be useful in the present invention include non-woven,continuous fiberglass veils, such as Firmat™ 100, Pearlveil™ 110,Pearlveil™ 210, Curveil™ 120, Curveil™ 220, Flexiveil™ 130, Flexiveil™230 and Pultrudable veil (all available from Schmelzer Industries, Inc.,Somerset, Ohio). The woven materials may be Airlaid™, Spunbond™ andNeedlepunch™ (available from BFG Industries, Inc. of Greensboro, N.C.).Nonlimiting examples of filament materials include D, E, B, C, DE, G, H,K filaments of various grades, including electrical grade, chemicalgrade and high strength grade (all available from BFG Industries, Inc.of Greensboro, N.C.). In a preferred embodiment, the substrate is awoven fiberglass mat. As used herein, a fiberglass mat includes nonwovenand woven fiberglass mats.

[0016] As stated above, the filler material of the present inventionpreferably includes clay. The clay may be Paragon™, which is soft clay(i.e. it is soft to the touch), Suprex™, which is hard clay (i.e. it ishard to the touch), Suprex™ amino silane treated clay, which is used forcrosslinking, since it will chemically bond with binder, and forhighloading and Ballclay™, which has elastic properties (i.e. it feelsrubbery). All of above-listed clay products are available, for example,from Kentucky-Tennessee Clay Company of Langley, S.C. In a preferredembodiment, the clay is Ballclay™ 3380 which is particularly inexpensivecompared to other clays. In the present invention, clay is preferredbecause of its elongation properties (it has a low modulus), itsabrasion resistance, its tear resistance, and its tensile strength.Moreover, clay is a good heat barrier; it does not disintergate when anopen flame (temperature≧1500° F.) is applied directly to a coating ofthe present invention that includes clay. In addition, clay provides aslick, elastic, glassy surface which exhibits flexibility. Furthermore,as noted, clay is inexpensive and thus can provide a low cost fabricmaterial.

[0017] The filler material may further comprise an additional fillerselected from the group consisting of decabromodiphenyloxide, antimonytrioxide, charged calcium carbonate, fly ash (such as Alsil O4TR™ classF fly ash produced by JTM Industries, Inc. of Martin Lake and Jewett,Tex. which has a particle size such that less than 0.03% remains on anagitated 0.1 inch×0.1 inch screen), 3-X mineralite mica (available fromEngelhard, Inc. of Louisville, Ky.) and glass or ceramic microspheres(glass microspheres are 2.5 times lighter than ceramic microspheres andalso provide fire resistance), or any mixture of these filler materialsto meet desired cost and weight criteria. Glass and ceramic microspheresare manufactured by Zeelan Industries of 3M Center Bldg., 220-8E-04, St.Paul, Minn. 55144-1000. Calcium carbonate may be obtained from FranklinIndustrial Minerals of 612 Tenth Avenue North, Nashville, Tenn. 37203.

[0018] Calcium carbonate, talc and fly ash filler increase the weight ofthe product, but utilization of glass and/or ceramic microspheresenables the manufacture of a product with reduced weight and increasedfire resistant properties. Clay may impart to the product the followingnonlimiting characteristics: (1) lower heat build-up, (2) heatreflectance properties, (3) fire barrier properties, (4) no weight losswhen exposed to heat and open flame, and (5) reduced disintegration whenexposed to heat and open flame. Decabromodiphenyloxide and antimonytrioxide impart the following nonlimiting characteristics: (1) flameretardant properties, (2) capability of forming a char, and (3)capability of stopping the spread of flames.

[0019] Glass and ceramic microspheres can withstand heat greater than2000° F. Also, glass and ceramic microspheres increase compressivestrength, absorb no latex and/or water and thus permit the faster dryingof the product. Glass and ceramic microspheres also increase productflexibility.

[0020] Further, the glass and ceramic microspheres help to increase thepot life of the coating. Heavier particles in the fillers, although theymay comprise but a small percentage of the particles in the filler, havea tendency to settle near the bottom of a storage vessel. When glassand/or ceramic microspheres are mixed together with another filler, adispersion is produced which has an increased pot life or shelf life.Without wishing to be bound by any particular theory, it is believedthat as the filler particles naturally fall in the vessel and the glassand ceramic microspheres rise, the smaller size filler particles aresupported by the glass and/or ceramic microspheres, thus enabling themicrospheres to stay in solution and preventing the filler particles, toat least some extent, from descending to the bottom of the vessel.

[0021] The use of the fire resistant fabric materials of the presentinvention for manufacturing fabrics for use in articles such asmattresses, cribs, drapes and upholstered furniture, may enable thearticle to exceed current flammability standards for these types ofarticles. While flammability standards for mattresses have notspecifically been set by the federal or state governments, somegovernment agencies have provided recommended guidelines.

[0022] For example, the United States Department of Commerce NationalInstitute of Standards and Technology (NTIS) in Gaithersburg, Marylandhas published a paper relating to a methodology for assessing theflammability of mattresses. See T. J. Ohlemiller et al., FlammabilityAssessment Methodology for Mattresses, NISTIR 6497, June 2000. While noclear standard is given, it is recommended that a mattress be able towithstand the described test procedures. The NTIS has noted that bedspose a unique fire hazard problem and provide a series of tests fordetermining the flammability of mattresses. In addition, the State ofCalifornia Department of Consumer Affairs Bureau of Home Furnishings andThermal Insulation (“the Bureau”) issued a Technical Bulletin in October1992 which provides a flammability test procedure for mattresses. SeeState of California Department of Consumer Affairs Bureau of HomeFurnishings and Thermal Insulation Technical Bulletin 129, October 1992,Flammability Test Procedure for Mattresses for use in Public Buildings.The technical bulletin provides standard methods for fire testing ofmattresses. The methods produce data describing the burning behaviorfrom ignition of a mattress until all burning has ceased, or after aperiod of one hour has elapsed. The rate of heat release is measured byan oxygen consumption technique. The Bureau indicates that mattressescomplying with the test method will be safer and hopes thatmanufacturers will attempt to manufacture mattresses which pass therecommended tests. The Bureau indicates that “a mattress fails to meetthe requirements of the test if any of the following criteria areexceeded:” (1) weight loss of 3 pounds or greater within the first 10minutes due to combustion, (2) a maximum rate of heat release of 100 kWor greater, and (3) a total heat release of 25 MJ or greater in thefirst 10 minutes. A mattress manufactured with the fire resistant fabricmaterial of the present invention is anticipated to comply with orexceed the test standards recommended both by the NTIS and theCalifornia Bureau. See Example 1 below.

[0023] As indicated above, the fire resistant fabric material of thepresent invention is usefull in the manufacture of mattresses. In thisembodiment of the invention, the fire resistant fabric material may beused to line a decorative fabric to produce a fire resistant mattressfabric. The lining may be achieved by methods known in the art. Forexample, the fire resistant fabric material of the present invention maysimply be placed under a decorative fabric. Or, the fire resistantmattress material may be adhered to the decorative fabric, for exampleusing a flexible and preferably nonflammable glue or stitched with fireresistant thread i.e., similar to a lining. The fire resistant mattressfabric of the present invention may then be used by the skilled artisanto manufacture a mattress which has improved flammabilitycharacteristics.

[0024] The table below provides, in percentages, the components of thecoating the applicants have used in a preferred embodiment of theinvention. TABLE I Coating Components % Wet % Dry BINDER BFG Hycar ™2679 Latex 25.000 23.123 Cymel ™ 373 3.700 5.877 Rhoplex ™ TR-407 4.5003.826 FILLER Clay-mattress grade 22.600 42.229 Antimony trioxide 3.0005.606 Decabromodiphenyloxide 9.000 16.817 WATER REPELLANT MATERIALNatrosol HEC ™ 0.050 0.093 Aurapel-391 ™ 2.500 1.168 Acrysol ™ ASE-95NP0.500 0.168 MISCELLANEOUS Water 27.470 0.000 Ammonium Hydroxide 1.1300.591 Y-250 defoamer 0.100 0.185 W-4123 Blue Pigment 0.500 0.318 TotalPercentage 100% 100%

[0025] Although the table shows possible combinations of clay,decabromodiphenyloxide and antimony trioxide in the filler component ofthe coating, it is believed that other combinations of clay with thefillers listed above may be employed. For example, thedecabromodiphenyloxide and antimony trioxide levels can be reducedand/or replaced with clay but the levels of these non-clay fillerconstituents are preferably not increased. Any changes in thecombination of fillers should maintain the density, viscosity, fireresistance properties and low cost coating. The density, viscosity andfire resistance properties can be ascertained by the skilled artisan andare further described in Example 1 below.

[0026] The coating is prepared by using a binder material such as a highperformance heat-reactive acrylic latex polymer to bond the fillermaterials together and to bond the filler to the substrate. Such abinder material is Hycar™ 2679 acrylic latex polymer supplied by B. F.Goodrich Company of Cleveland, Ohio. Binder components may also includeCymel™ 373 (available from American Cyanamid), RHOPLEX™ TR 407 and R&HGL-618 latex both available from Rohm & Haas, and Borden FG-413F UFresin (available from Borden). It is believed, however, that any linearpolymer, linear copolymer or branched polymer may be useful in preparingthe coating. Possible binder materials include butyl rubber latex, SBRlatex, neoprene latex, polyvinyl alcohol emulsion, SBS latex, waterbased polyurethane emulsions and elastomers, vinyl chloride copolymers,nitrile rubbers and polyvinyl acetate copolymers.

[0027] The coating comprises approximately 50% by weight of the fireresistant fabric material. In the coating, about 20% to about 80% byweight is filler and from about 80% to about 20% is acrylic binder. In apreferred embodiment, the coating comprises about 50% filler and about50% binder. The filler is preferably about 65% clay, 26%decabromodiphenyloxide, and 9% antimony trioxide. The substrate ispreferably comprised of about 75% by dry weight Owens-Corning H Glass ½″and 25% by dry weight Evanite 719 Glass Microfiber. The substrate mayalso be, for example, a woven fabric of DE, E, H, or G filamentavailable from BFG Industries. The substrate is approximately 50% byweight of the fire resistant fabric material. The binder which bondstogether the glass fibers is approximately 100% B. F. Goodrich 2679Acrylic Latex, but binder components may also include Cymel 373, citricacid, Rohm & Haas GL-618 Latex and Borden FG-413F UF Resin.

[0028] The substrate may be coated by air spraying, dip coating, knifecoating, roll coating or film application such as lamination/heatpressing. The coating may be bonded to the substrate by chemicalbonding, mechanical bonding and/or thermal bonding. Mechanical bondingis achieved by force feeding the coating onto the substrate with aknife.

[0029] Fire resistant fabric materials made in accordance with thisinvention may be of any shape. Preferably, such articles are planar inshape. The fire resistant fabric materials may be used in any of avariety of products, including, but not limited to mattress/cribfabrics, mattress/crib covers, upholstered articles, bedroom articles,(including children's bedroom articles), draperies, carpets, wallcoverings (including wallpaper) tents, awnings, fire shelters, sleepingbags, ironing board covers, fire resistant gloves, fire-resistantclothing for race car drivers, fire fighters, jet fighter pilots, andthe like, building materials, such as roofing shingles, structurallaminate facing sheets, building air duct liners, roofing underlayment(or roofing felt), underlayment for organic, built up roofing materials,roll roofing, modified roll products, filter media (including automotivefilters), automotive hood liners, head liners, fire walls, vaporbarriers etc.

[0030] The fire resistant fabric material may be used alone or may beused as a liner for a decorative fabric, such as the type used formattresses, drapes, sleeping bags, etc. which may also be fireresistant.

[0031] The substrate may be coated on one side or both sides dependingon the intended application. For instance, if one side of the substrateis coated with the filler/binder coating, the other surface can becoated with another material. In the roofing materials industry, forexample, the other material may be conventional roofing asphalt,modified asphalts and non-asphaltic coatings, and the article can thenbe topped with roofing granules. It is believed that such roofingmaterial could be lighter in weight, offer better fire resistance andbetter performance characteristics (such as cold weather flexibility,dimensional stability and strength) than prior art roofing materials.

[0032] Additionally, the fire resistant fabric material may be coatedwith a water repellent material or the water repellent material may beadded in the coating (i.e., internal water proofing). Two such waterrepellent materials are Aurapel™ 330R and Aurapel™ 391 available fromSybron/Tanatex of Norwich, Conn. In addition, Omnova Sequapel™ andSequapel 417 (available from Omnovasolutions, Inc. of Chester, S.C.);BS-1306, BS-15 and BS-29A (available from Wacker of Adrian, Mich.);Syl-off™-7922, Syl-off™-1171A, Syl-off™-7910 and Dow Corning 346Emulsion (available from Dow Corning, Corporation of Midland, Mich.);Freepel™-1225 (available from BFG Industries of Charlotte, N.C.); andMichem™ Emulsion-41740 and Michem™ Emulsion-03230 (available fromMichelman, Inc. of Cincinnati, Ohio) may also be used. It is believedthat wax emulsions, oil emulsions, silicone emulsions, polyolefinemulsions and sulfonyls as well as other similar performing products mayalso be suitable water repellent materials.

[0033] A defoamer may also be added to the coating of the presentinvention to reduce and/or eliminate foaming during production. One suchdefoamer is Drew Plus Y-250 available from Drews Industrial Division ofBoonton, N.J. In addition, ionic materials may be added to increase theionic charge of the coating, such as ammonium hydroxide, Natrosol-HEC™available from Hercules of Wilmington, Del.) and ASE-95NP and ASE-60(available from Rohm & Haas of Charlotte, N.C).

[0034] Further, fire resistant fabric materials made in accordance withthe invention may be coated with an algaecide such as zinc powder,copper oxide powder or the herbicides Atrazine available from e.g.Ribelin Industries or Diuron available from e.g. Olin Corporation, anantifungal material such as Micro-Chek™ 11P, an antibacterial materialsuch as Micro-Chek™ 11-S-160, a surface friction agent such as Byk™-375,a flame retardant material such as ATH (aluminum trihydrate) availablefrom e.g. Akzo Chemicals and antimony trioxide available from e.g.Laurel Industries. In addition, color pigments, including, but notlimited to, T-113 (Abco, Inc.), W-4123 Blue Pigment, W2090 OrangePigment, W7717 Black Pigment and W6013 Green Pigment, iron oxide redpigments (available from Engelhard of Louisville, Ky.) may also be addedto the coating of the present invention to impart desiredcharacteristics, such as a desired color. The Micro-Chek™ products areavailable from the Ferro Corporation of Walton Hills, Ohio Byk-375 maybe obtained from Wacker Silicone Corporation of Adrian, Mich. andT-1133A is sold by Abco Enterprises Inc. of Allegan, Mich.

[0035] The additional coatings of, e.g. water repellent material,antifungal material, antibacterial material, etc., may be applied to oneor both sides of fire resistant fabric materials otherwise havingfiller/binder coatings on one or both sides of the substrate. Forexample, fire resistant fabric materials comprising substrates coated onone or both sides with filler/binder coatings could be coated on oneside with a water repellent composition and on the other side with anantibacterial agent. Alternatively, the water repellant material,antifungal material, antibacterial material, etc., may be added to thecoating before it is used to coat the substrate.

[0036] Foamed fire resistant fabric materials made in accordance withthe present invention may be made by any of the known methods for makingfoamed compositions such as, for example, aeration by mechanical mixingand the other techniques described in U.S. Pat. No. 5,110,839.

EXAMPLE I

[0037] To produce the fire resistant fabric materials of the presentinvention, the applicant formulated the coating using just three majorcomponents, water, filler and binder (see Table I above). The amounts ofthe major constituents were as follows: approximately 28% water, 25%Hycar 2679, and 23% clay (dry percentages are 0%, 23% and 42%respectively). Additional filler materials, decabromodiphenyloxide(approximately 9% of the wet formula weight and 16% of the dry formulaweight) and antimony trioxide (approximately 3% of the wet formulaweight and 5.6% of the dry formula weight) were also added. The bindersCymel 373 (approximately 3.7% wet/5,9% dry) and Rhoplex TR-407(approximately 4.5% wet and 3.8% dry) were also used. In total, thebinder and filler made up 59.6% wet and 47.10% dry of the total coating.Dye and defoaming agent made up less than 1% of the dry formulation,water repellant made up less than 2% of the dry formulation, ionicmaterial (ammonium hydroxide) made up less than 1% of the dryformulation and defoaming agent made up less than 0.2% of the dryformulation. The defoaming agent was Drew Plus Y-250. The materials weremixed in a reaction or mixing kettle for 45 minutes.

[0038] The coating was used to coat a fiberglass mat on one and bothsides. The mat was manufactured by Elk Corporation of Ennis, Tex. andhad a basis weight in the range of 1.4 lb./sq. to 2.0 lb./sq. The mathad a porosity in the range of 800 to 1,000 cfm/ft². Generally, whensuch highly porous mats have been coated on one side only, the coatingbleeds through to the other side. In accordance with the presentinvention however, the novel coating comprising clay coated the surfaceof the fiberglass mat very well and did not bleed through to the otherside of the mat. The coated article was durable and flexible and did notcrack on bending. Typical tensile strength measurements for uncoatedversus coated were 75 lbs/3″ and 217 lbs/3″ respectively. TypicalElmendorff tear strength measurements were≧3200 grams without the sampletearing.

[0039] The fire resistant fabric material was checked forcombustibility. When exposed to the flame of a Bunsen Burner from adistance of two inches, woven fabric and wet lay fabric failed the firetest (i.e. the glass fiber melted or a hole was created where the flamehit the fabric). However, when the fire resistant fabric material of thepresent invention was exposed to the flame of a Bunsen Burner from adistance of two inches for a period of five minutes or more, no hole wascreated and the glass fibers did not melt. The coating protected theglass fabric from melting or disintegrating and the integrity of theglass fabric structure was maintained. The Technical Bulletin 129 of theState of California Department of Consumer Affairs Bureau of HomeFurnishings and Thermal Insulation (October 1992) indicates that afabric should maintain integrity when exposed to an open flame for 20minutes and that test was passed in the lab with the present invention.

[0040] Surprisingly, when the coating of the present invention was usedto coat the fiberglass mat on one side, it did not bleed through to theother side even though the coating had a relatively low viscosity ofapproximately 1000 cp. Although not wishing to be bound by anyparticular theory, the applicant believes that the coating did not bleedthrough the mat because the fiberglass mat is anionic and the coating ofthe present invention (when wet) includes a combination of water andHycar 2679 (which together are anionic) and clay filler (which is madeanionic by the presence of antimony trioxide). The addition of theammonium hydroxide increased the anionic charge of the coating. Theresultant formulation had a low viscosity believed to be due to therepulsion of charges of the anionic latex in water and the anionicclay/ammonium hydroxide. Although low viscosity is not a desiredobjective for coating a highly porous mat, the unique characteristic ofthe invention is that the coating does not bleed through regardless ofthe viscosity because the mat is also anionic and like charges repeleach other just as the north pole of one magnet repels the north pole ofanother magnetic.

[0041] If desired, however, the viscosity of the coating can beincreased through mixing. The water and latex solution to which fillerand ammonium hydroxide were added is acidic in nature and, on prolongedmixing, there is some hydrolysis thereby increasing the viscosity of thecoating. The longer or the more rapidly the coating is mixed, the higherthe viscosity. However, the coating still maintains an essentiallyanionic charge and thus there is still repelling of charges between thecoating and the substrate.

[0042] Whether slowly or rapidly mixed, the coatings of the presentinvention may be applied to the substrates in relatively uniform thincoats because the like charges among the filler and acrylic latexelements in the coating repel one another. Thus, it is believed that theionic charge repulsion characteristic which prevents the coating frombleeding through the mat also enables the application on the mat of arelatively uniform thin film coating. In instances where, due to price,supply or other considerations, the filler material to be employed hasan ionic charge which is essentially the opposite of the charge of thesubstrate, modifiers are available to coat the filler material so thatultimately the coating and substrate of the article have essentially thesame ionic charge. It is believed that viscosity modifiers could servesuch a purpose.

[0043] The invention provides a fire resistant fabric material which isflexible, pliable has good drapability characteristics and which showsno signs of cracking, etc. The coated fabric has a porosity of less than10.4 cfm (uncoated has a porosity of 440 cfm) and adheres very well toother materials, including decorative fabrics, polyurethane foam,isocyanurate foam, asphaltic compounds, and granules (non-asphalticshingle components).

[0044] The coated product may have few pinholes or may have numerouspinholes and still maintain a porosity of less than from approximately 5to approximately 50 cfm when coated with solvent based adhesive such asFirestone Bonding Adhesive BA-2004 which does not bleed through thecoated product.

[0045] The fire resistant fabric materials were made water repellent byadding to the coating the water repellent materials listed above. Theapplication of the coating to the substrate was accomplished by dilutingthe coating compound with water and then kiss coating the articles onone side while they were being coated on the other side by standardcoating techniques which included the use of a doctor blade. The coatingmay also be performed by dip coating, scraping with a blade, orsqueezing between two rolls having a gap that determines the thicknessof the coating.

[0046] Prior to coating with a water repellent coating, the novelcoating of the present invention can be treated with pigment or dye orany other suitable coloring means to give color to the fire resistantfabric materials of the invention. For instance, a W-4123 Blue Pigment(available from Engelhard of Louisville, Ky.) (0.5% by wet weight) wasadded to the coating composition to give color texture to the finishedcoating on the fiberglass mat.

[0047] Besides water repellent treatment, the fire resistant fabricmaterials of the present invention can be coated with antifungal,antibacterial and surface friction agents, an algaecide and/or a flameretardant material by mixing with the coating constituents prior tocoating the substrate or by spraying on the partly finished articles atsome point in the processing, e.g. between drying and curing.

[0048] Coating of the fiberglass substrates was accomplished using ahand-held coater which can be obtained from the Gardner Company, but anyconventional method, such as spraying, dipping and flow coating fromaqueous or solvent dispersion, calendering, laminating and the like,followed by drying and baking, may be employed to coat the substrate asis well known in the art. Best coating results were observed using aGardner profile 10 blade. After coating, the samples were placed in anoven at approximately 400° for about 2.0 minutes to achieve drying andcuring. Additionally, the coating may be separately formed as a film ofone or more layers for subsequent combination with the substrate.

[0049] Hycar™ 2679 acrylic latex polymer has a low Brookfield viscosityof 100 cP. The low viscosity makes the polymer easily miscible withwater and filler. This heat reactive acrylic polymer is compatible withall fillers due to its anionic charge. Products made with coatings whichinclude the polymer are flexible at extreme high and low temperaturesbecause the polymer has a glass transition temperature (Tg) of −3 C.

[0050] Hycar™ 2679 polymer emulsion contains a colloidal dispersion ofpolymer and copolymers in water, emulsifiers, such as synthetic soap(sometimes known as surface active agents or surfactants) and otheringredients such as buffers and protective colloids. These ingredientsenable the polymer to be compatible with a wide variety of fillers.Without being bound to any particular theory, it is believed that Hycar™2679, with its thixotropic characteristics, enhances the viscosity ofmost fillers.

[0051] It is believed that a preferred embodiment is prepared bycombining constituents in the following wet amounts: 27.47% water, 25%Hycar™ 2679 acrylic latex, 3.7% Cymel™ 373, 4.5% RHOPLEX™ TR-407, 22.6%mattress grade clay, 3% antimony trioxide, 9% decabromodiphenyloxide,0.05% Natrosol™ HEC, 2.5% Aurapel™-391, 0.5% Acrysol™ ASE-95NP, 1.13%ammonium hydroxide, 0.1% Y-250 defoamer and 0.5% W4123 Blue Pigment.

[0052] It should be understood that the above examples are illustrative,and that compositions other than those described above can be used whileutilizing the principals underlying the present invention. For example,other sources of filler as well as mixtures of acrylic latex and/orsurfactants can be used in formulating the fire resistant fabricmaterials of the present invention. Moreover, the coating compositionscan be applied to various types of substrates, as described above.

What is claimed is:
 1. A fire resistant fabric material comprising asubstrate having an ionic charge coated with a coating havingessentially the same ionic charge wherein said coating consistsessentially of a filler material comprising clay and a binder materialand wherein said binder material bonds the filler material together andto the substrate and wherein said coating does not bleed through saidsubstrate.
 2. The fire resistant fabric material according to claim 1wherein said substrate is fiber-glass, said filler further comprises atleast one other filler selected from the group consisting ofdecabromodiphenyloxide, antimony trioxide, fly ash, charged calciumcarbonate, mica, glass microspheres and ceramic microspheres and saidbinder is acrylic latex.
 3. The fire resistant fabric material accordingto claim 2 wherein said substrate is planar and is coated on one sidewith said coating.
 4. The fire resistant fabric material according toclaim 2 wherein said substrate is planar and is coated on both sideswith said coating.
 5. The fire resistant fabric material according toclaims 1, 3 or 4, wherein said material further includes on one or bothsides a water repellent material.
 6. The fire resistant fabric materialaccording to claims 1, 3 or 4 wherein said material further includes onone or both sides an antifungal material.
 7. The fire resistant fabricmaterial according to claims 1, 3 or 4 wherein said material furtherincludes on one or both sides an antibacterial material.
 8. A fireresistant fabric material according to claims 1, 3 or 4 wherein saidmaterial further includes on one or both sides a surface friction agent.9. A fire resistant fabric material according to claims 1, 3 or 4wherein said material further includes on one or both sides a flameretardant material.
 10. A fire resistant fabric material according toclaims 1, 3 or 4 wherein said material further includes on one or bothsides an algaecide.
 11. A fire resistant fabric material according toclaims 1, 3 or 4 wherein said material is colored with dye.
 12. A fireresistant fabric material comprising a substrate coated with a coatingconsisting essentially of a filler material comprising clay and a bindermaterial wherein a) said substrate comprises glass fibers and whereinsaid material is from 65% to 90% by weight of the glass fibers; and b)said coating is from 20% to 80% wet weight of filler and from 80% to 20%wet weight of acrylic latex binder material.
 13. The fire resistantfabric material according to claim 12 wherein said filler furthercomprises at least one filler selected from the group consisting ofdecabromodiphenyloxide, antimony trioxide, mica, fly ash, chargedcalcium carbonate, glass microspheres and ceramic microspheres.
 14. Afire resistant mattress fabric comprising a decorative fabric and a fireresistant fabric material which comprises a substrate having an ioniccharge coated with a coating having essentially the same ionic chargewherein said coating consists essentially of a filler materialcomprising clay and a binder material and wherein said binder materialbonds the filler material together and to the substrate and wherein saidcoating does not bleed through said substrate.
 15. A fire resistantmattress fabric comprising a decorative fabric and a fire resistantfabric material which comprises a substrate coated with a coatingconsisting essentially of a filler material comprising clay and a bindermaterial wherein a) said substrate comprises glass fibers and whereinsaid material is from 65% to 90% by weight of the glass fibers; and b)said coating is from 20% to 80% wet weight of filler and from 80% to 20%wet weight of acrylic latex binder material.
 16. A mattress comprising afire resistant fabric material which comprises a substrate having anionic charge coated with a coating having essentially the same ioniccharge wherein said coating consists essentially of a filler materialcomprising clay and a binder material and wherein said binder materialbonds the filler material together and to the substrate and wherein saidcoating does not bleed through said substrate.
 17. A mattress comprisinga fire resistant fabric material which comprises a substrate coated witha coating consisting essentially of a filler material comprising clayand a binder material wherein a) said substrate comprises glass fibersand wherein said material is from 65% to 90% by weight of the glassfibers; and b) said coating is from 20% to 80% wet weight of filler andfrom 80% to 20% wet weight of acrylic latex binder material.
 18. Amattress comprising a fire resistant fabric material having a decorativefabric and a fire resistant fabric material which comprises a substratehaving an ionic charge coated with a coating having essentially the sameionic charge wherein said coating consists essentially of a fillermaterial comprising clay and a binder material and wherein said bindermaterial bonds the filler material together and to the substrate andwherein said coating does not bleed through said substrate.
 19. Amattress comprising a fire resistant fabric material having a decorativefabric and a fire resistant fabric material which comprises a substratecoated with a coating consisting essentially of a filler materialcomprising clay and a binder material wherein a) said substratecomprises glass fibers and wherein said material is from 65% to 90% byweight of the glass fibers; and b) said coating is from 20% to 80% wetweight of filler and from 80% to 20% wet weight of acrylic latex bindermaterial.